Implement and method of forming the same

ABSTRACT

An implement having a base structure with a core component and a shell component that surrounds the core component. The core component may include a body formed of a rigid material and decorative elements embedded within the body. The shell component may be formed of a substantially transparent material so that the decorative elements of the core are visible through the shell component.

CROSS-REFERENCE TO RELATED APPLICATIONS

The present application is a continuation of U.S. patent applicationSer. No. 14/755,230, filed Jun. 30, 2015, which is acontinuation-in-part of U.S. patent application Ser. No. 14/400,956,filed Nov. 13, 2014, which is a U.S. national stage application under 35U.S.C. § 371 of Patent Cooperation Treaty Application No.PCT/US2012/038235, filed May 17, 2012, the entireties of which areincorporated herein by reference.

BACKGROUND

The oral care implement industry is rather competitive and innovation ofan oral care implement with desirable aesthetics can be financiallybeneficial to a seller of such products. Although designing an oral careimplement with improved gripability and cleaning benefits may provide aseller of such products with additional marketing terminology, in theend it is often the look of an oral care implement that drives sales.Current trends to enhance the aesthetics of oral care implementsincludes forming oral care implements in multiple mold cavities or outof multiple components that must be coupled together, which increasesthe time and expense required to manufacture such oral care implements.Thus, a need exists for an oral care implement with a desirable andattractive appearance that is eye catching and simple in design so thatmanufacturing costs may be reduced and sales increased.

BRIEF SUMMARY

The present invention may be directed, in one aspect, to an implementhaving a base structure that includes a core component and a shellcomponent. The core component may include a body and decorative elementstherein. The shell component may be a transparent rigid material. Thus,the decorative elements of the core component are visible through theshell component to achieve a desirable aesthetic effect. In otherembodiments the present invention may be directed to a method of formingsuch an implement.

In one embodiment, the invention can be an implement comprising: a basestructure comprising a core component and a shell component, the shellcomponent encapsulating the core component and forming an outer surfaceof the base structure; the shell component formed of a substantiallytranslucent first material; the core component comprising a body formedof a rigid material and a plurality of decorative elements embeddedwithin the rigid material, at least one of the plurality of decorativeelements forming a portion of an outer surface of the core component,the at least one of the plurality of decorative elements of the corecomponent being visible through the substantially translucent firstmaterial of the shell component; and wherein the plurality of decorativeelements comprises discrete particles.

In another embodiment, the invention can be an implement comprising: abase structure comprising a core component and a shell componentsurrounding the core component; the shell component and a body of thecore component being formed of a substantially transparent first rigidmaterial; and the core component comprising a plurality of decorativeelements embedded within and dispersed throughout the body and visiblethrough the shell component and the body of the core component; andwherein the shell component is free of any decorative elements.

In yet another embodiment, the invention can be a method of forming animplement comprising: a) providing a first mold that defines a firstmold cavity, the first mold cavity having a shape that corresponds witha shape of a base structure of the implement; b) injecting a firstmaterial into the first mold cavity, the first material beingtransparent or translucent; and c) injecting a second material into thefirst material in the first mold cavity, thereby displacing the firstmaterial within the first mold cavity and forming the base structure,the second material forming a core component of the base structure andthe first material forming a shell component of the base structure thatsurrounds the core component; and wherein a plurality of decorativeelements are dispersed throughout the second material of the corecomponent and visible through the first material of the shell component.

Further areas of applicability of the present invention will becomeapparent from the detailed description provided hereinafter it should beunderstood that the detailed description and specific examples, whileindicating the preferred embodiment of the invention, are intended forpurposes of illustration only and are not intended to limit the scope ofthe invention.

BRIEF DESCRIPTION OF THE DRAWINGS

The present invention will become more fully understood from thedetailed description and the accompanying drawings, wherein:

FIG. 1 is a front perspective view of an oral care implement inaccordance with a first embodiment of the present invention.

FIG. 2 is a rear view of the oral care implement of FIG. 1.

FIG. 3 is a cross-sectional view taken along line III-III of FIG. 1.

FIG. 4A is a cross-sectional view taken along line IV-IV of FIG. 3.

FIG. 4B is a cross-sectional view taken along line IV-IV of FIG. 3 inaccordance with an alternative embodiment of the present invention.

FIG. 5 is a front perspective view of an oral care implement inaccordance with a second embodiment of the present invention.

FIG. 6 is a rear view of the oral care implement of FIG. 5.

FIG. 7 is a cross-sectional view taken along line VII-VII of FIG. 6.

FIG. 8 is a front perspective view of an oral care implement inaccordance with a third embodiment of the present invention.

FIG. 9 is a rear view of the oral care implement of FIG. 8.

FIG. 10 is a cross-sectional view taken along line X-X of FIG. 9.

FIG. 11 is a schematic cross-sectional view of a first mold defining afirst mold cavity and coupled to material injection subsystems.

FIG. 12 is a schematic cross-sectional view of the first mold of FIG.11, wherein a first material is being injected into the first moldcavity.

FIG. 13 is a schematic cross-sectional view of the first mold of FIG.11, wherein a second material is being injected into the first moldcavity to form a base structure of an oral care implement.

FIG. 14 is a schematic cross-sectional view of the base structure ofFIG. 13 positioned within a second mold, wherein a third material isbeing injected into a second mold cavity of the second mold.

FIG. 15 is a schematic cross-sectional view of the oral care implementpositioned within the second mold cavity of the second mold.

DETAILED DESCRIPTION

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention,its application, or uses.

The description of illustrative embodiments according to principles ofthe present invention is intended to be read in connection with theaccompanying drawings, which are to be considered part of the entirewritten description. In the description of embodiments of the inventiondisclosed herein, any reference to direction or orientation is merelyintended for convenience of description and is not intended in any wayto limit the scope of the present invention. Relative terms such as“lower,” “upper,” “horizontal,” “vertical,” “above,” “below,” “up,”“down,” “top” and “bottom” as well as derivative thereof (e.g.,“horizontally,” “downwardly,” “upwardly,” etc.) should be construed torefer to the orientation as then described or as shown in the drawingunder discussion. These relative terms are for convenience ofdescription only and do not require that the apparatus be constructed oroperated in a particular orientation unless explicitly indicated assuch. Terms such as “attached,” “affixed,” “connected,” “coupled,”“interconnected,” and similar refer to a relationship wherein structuresare secured or attached to one another either directly or indirectlythrough intervening structures, as well as both movable or rigidattachments or relationships, unless expressly described otherwise.Moreover, the features and benefits of the invention are illustrated byreference to the exemplified embodiments. Accordingly, the inventionexpressly should not be limited to such exemplary embodimentsillustrating some possible non-limiting combination of features that mayexist alone or in other combinations of features; the scope of theinvention being defined by the claims appended hereto.

As used throughout, ranges are used as shorthand for describing each andevery value that is within the range. Any value within the range can beselected as the terminus of the range. In addition, all references citedherein are hereby incorporated by reference in their entireties. In theevent of a conflict in a definition in the present disclosure and thatof a cited reference, the present disclosure controls.

Referring first to FIGS. 1 and 2 concurrently, an oral care implement100 is illustrated in accordance with one embodiment of the presentinvention. In the exemplified embodiment, the oral care implement 100 isin the form of a manual toothbrush. However, in certain otherembodiments the oral care implement 100 can take on other forms such asbeing a powered toothbrush, a tongue scraper, a gum and soft tissuecleanser, a water pick, an interdental device, a tooth polisher, aspecially designed ansate implement having tooth engaging elements, orany other type of implement that is commonly used for oral care.Furthermore, in still other embodiments the implement may not be limitedto one that is used for oral care, and may be any type of personal careimplement such as a manual or electric razor, a hairbrush, or the like.Thus, it is to be understood that the inventive concepts discussedherein can be applied to any type of oral or personal care implementunless a specific type of oral or personal care implement is specifiedin the claims.

In the exemplified embodiment, the oral care implement 100 comprises abase structure 110 and an elastomeric overmold 160. The base structure110 is formed of one or more rigid plastic materials such as for examplewithout limitation polymers and copolymers of ethylene, propylene,butadiene, vinyl compounds, polyesters such as polyethyleneterephthalate (PET), styrene-acrylonitrile (SAN), polyurethane,polyamide, cellulosic, acrylic, acrylonitrile butadiene styrene (ABS),or the like. The base structure 110 has an outer surface 113 and theelastomeric overmold 160 is coupled to the outer surface 113 such as byinjection molding, adhesion, fasteners, or the like.

In certain embodiments the elastomeric overmold 160 may form a grip toprevent slippage and enhance comfort during use of the oral careimplement 100, although the elastomeric overmold 160 may also be omittedin certain embodiments as desired. The elastomeric overmold 160 may beformed of a thermoplastic elastomer or other rubber-like material thatenhances comfort and gripability of the oral care implement 100 duringuse. Although in the exemplified embodiment the elastomeric overmold 160is only illustrated in a strip on the rear surface of the handle portion111 of the base structure 110, the invention is not to be so limited. Inother embodiments the elastomeric overmold 160 may extend onto the frontsurface of the base structure 110 to form a forefinger and thumb grip toincrease comfort and prevent slippage during use. Furthermore, theelastomeric overmold 160 may extend onto the rear surface of the headportion 112 of the base structure 110 to operate as a tongue and softtissue cleanser. The elastomeric overmold 160 may also extend onto thefront surface of the head portion of the base structure 110 to operateas a rubber tooth polishing member. The elastomeric overmold 160 may bea single unitary piece formed via a single shot in an injection mold ormay include several discontinuous or separated segments formed of theelastomeric material via multiple shots in an injection mold.Furthermore, various textures, protrusions, channels, ridges, or thelike may be formed as part of the elastomeric overmold 160.

In certain exemplified embodiments, the base structure 110 comprises ahandle portion 111 and a head portion 112. The handle portion 111 of thebase structure 110 extends from a proximal end 101 of the oral careimplement 100 to a distal end 102 of the handle portion 111. Thus, inthe exemplified embodiment the handle portion 111 includes the portionof the oral care implement 100 that is gripped during use and a neck 105of the oral care implement 100 that forms the transition region betweenthe handle portion 111 and the head portion 112. The handle portion 111of the base structure 110 is an elongated structure that provides themechanism by which the user can hold and manipulate the oral careimplement 100 during use. In the exemplified embodiment, the handleportion 111 is generically depicted having various contours for usercomfort. Of course, the invention is not to be limited by the specificshape illustrated for the handle portion 111 in all embodiments and incertain other embodiments the handle portion 111 can take on a widevariety of shapes, contours, and configurations, none of which arelimiting of the present invention unless so specified in the claims.

The head portion 112 of the base structure 110 extends from the distalend 102 of the handle portion 111 to a distal end 103 of the headportion 112. In the exemplified embodiment, a plurality of toothcleaning elements 115 are coupled to and extend from the head portion112 of the base structure 110. The term “tooth cleaning elements” isused in a generic sense to refer to any structure that can be used toclean, polish, or wipe the teeth and/or soft oral tissue (e.g. tongue,cheek, gums, etc.) through relative surface contact. Common examples of“tooth cleaning elements” include, without limitation, bristle tufts,filament bristles, fiber bristles, nylon bristles, spiral bristles,rubber bristles, elastomeric protrusions, flexible polymer protrusions,combinations thereof and/or structures containing such materials orcombinations. The tooth cleaning elements may include tapered bristles,non-tapered (i.e., end rounded) bristles, and combinations thereof. Anycombination of the various types of tooth cleaning elements may be usedon the oral care implement 100 in different embodiments.

In embodiments that use elastomeric elements as one or more of the toothcleaning elements 115, suitable elastomeric materials may include anybiocompatible resilient material suitable for uses in an oral hygieneapparatus. To provide optimum comfort as well as cleaning benefits, theelastomeric material of any such tooth or soft tissue engaging elementsmay have a hardness property in the range of A8 to A25 Shore hardness.One suitable elastomeric material is styrene-ethylene/butylene-styreneblock copolymer (SEBS) manufactured by GLS Corporation. Nevertheless,SEBS material from other manufacturers or other materials within andoutside the noted hardness range could be used. The tooth cleaningelements 115 may be coupled to the head portion 112 of the basestructure 110 using any technique known in the art, such as stapling,anchor free tufting, in-mold tufting, AMR, or the like. The invention isnot to be limited by the manner in which the tooth cleaning elements 115are coupled to the head portion 112 in all embodiments.

The head portion 112 of the oral care implement 100 is coupled to thehandle portion 111 and comprises a front surface 116 and an opposingrear surface 117. The tooth cleaning elements 115 extend from the frontsurface 116 of the head portion 112. A tongue or soft tissue cleaner(not depicted) may be positioned on the rear surface 117 of the headportion 112. In the exemplified embodiment, the head portion 112 isformed integrally with the handle portion 111 as a single unitarystructure using a molding, milling, machining, or other suitableprocess. However, in other embodiments the handle portion 111 and thehead portion 112 may be formed as separate components which are operablyconnected at a later stage of the manufacturing process by any suitabletechnique known in the art, including without limitation thermal orultrasonic welding, a tight-fit assembly, a coupling sleeve, threadedengagement, adhesion, or fasteners. Thus the handle portion 111 and thehead portion 112 may, in certain embodiments, be formed of any of therigid plastic materials described above, although the invention is notto be so limited in all embodiments and other materials that arecommonly used during toothbrush manufacture may also be used.

Referring to FIGS. 1-4A concurrently, the oral care implement 100 willbe further described. The base structure 110 of the oral care implement100 extends from the proximal end 101 of the handle portion 111 to thedistal end 103 of the head portion 112 along a longitudinal axis A-A.The base structure 110 of the oral care implement 100 comprises a shellcomponent 120 and a core component 130. In the exemplified embodiment,only the handle portion 111 of the base structure 110 comprises theshell and core components 120, 130 and the head portion 112 of the basestructure 110 comprises only the shell component 120. Thus, in certainembodiments the shell component 120 and the core component 130collectively form the handle portion 111 of the base structure 110.However, in the exemplified embodiment the core component 130 does notextend to the head portion 112 of the base structure 110. Thus, in theexemplified embodiment the shell component 120 forms an entirety of thehead portion 112 of the base structure 110.

Stated another way, the base structure 110 has a length L₁ measured fromthe distal end 101 of the handle portion 101 to the distal end 103 ofthe head portion 112. The shell component 120 extends the entire lengthL₁ of the base structure 110. The core component 130 has a length thatis less than the length L₁ of the base structure 110 so that althoughthe core component 130 extends from adjacent to the proximal end 101 ofthe base structure 110, the core component 130 does not extend into thehead portion 112 of the base structure 110. Of course, the length L₂ ofthe core component 130 may be adjusted in certain embodiments so thatthe core component 130 may extend into the head portion 112 in someembodiments if so desired. The core component 130 is elongated in adirection of the longitudinal axis A-A and may taper in a directiontowards the head portion 112. The core component 130 may extend along anentirety of the handle portion 111 of the base structure 110 andapproximately two-thirds to three-fourths of the length L₁ of the basestructure 110. Thus, a ratio L₁:L₂ may be between 1.3:1 to 1.5:1, ormore specifically 1.35:1 to 1.45:1.

The core component 130 forms an interior longitudinal section of thebase structure 110 and the shell component 120 forms an exteriorlongitudinal section of the base structure 110. Thus, at any transverseplane taken through the base structure 110 that intersects both theshell and core components 120, 130, the shell component 120 has adiameter that is greater than a diameter of the core component 130.Thus, the shell component 120 substantially surrounds the core component120. More specifically, the core component 130 is substantially entirelysurrounded or enclosed by the shell component 120. Stated another way,the core component 130 is circumferentially surrounded by the shellcomponent 120 along its entire length so that no portion of the corecomponent 130 is exposed. In the exemplified embodiment, the shellcomponent 120 completely surrounds the core component 120 so that theentire outer surface 113 of the base structure 110 is formed by theshell component 120 and no portion of the core component 130 extends toand is exposed on the outer surface 113 of the base structure 110.

Thus, the core component 130 appears to float within the shell component120. The shell component 120 may be formed of a transparent material andthe core component 130 may be formed of an opaque material (or atranslucent material or a tinted material) so that the core component130 is visible through the shell component 120 to achieve a desirableaesthetic effect. As discussed in more detail below, the core component130 may comprise a body 131 and a plurality of decorative elements 132that are visible through the shell component 120 to enhance theaesthetic effect. The plurality of decorative elements 132 may bedispersed throughout the body 131 or located within certain regions ofthe body 131.

In the exemplified embodiment the core component 130 tapers towards thehead portion 112 of the base structure 110 such that the cross-sectionalarea of the core component 130 decreases as the core component 130extends away from the proximal end 101 of the handle portion 111 of thebase structure 110 towards the head portion 112 of the base structure110. However, the invention is not to be limited by the shape, length,thickness, and size of the core component 130 in all embodiments unlessspecifically claimed as such. The core component and shell component120, 130 of the base structure 110 can be formed using sandwich moldingtechnologies in a single mold cavity as described in more detail belowwith reference to FIGS. 11-13, or by using multiple mold cavityinjection molding processes.

In the exemplified embodiment, the shell component 120 comprises asubstantially translucent first material. As used herein, the termtranslucent may include materials that are translucent that transmit anddiffuse light so that objects cannot be seen clearly through thematerial and materials that are transparent and allow all light to passthrough so that objects can be seen clearly through the material. Theterm translucent does not include materials that are opaque such thatobjects cannot be seen through the material at all. Thus, as used hereintranslucent should be interpreted to mean translucent and/ortransparent. Materials that are translucent may be tinted. Specifically,in some embodiments the first material of the shell component 120 may betinted and translucent. Tinted/translucent materials may be desirablefor the shell component 120 to add to the aesthetics of the oral careimplement 100. When the term transparent is used herein it should beunderstood to mean transparent but not also translucent. In someembodiments transparent materials may be desired for the shell component120 to ensure that the core component 130 and the decorative elements132 dispersed within the body 131 thereof are readily visible throughthe shell component 120.

Furthermore, the first material is a rigid material because it forms themain structure of the handle portion 111 and head portion 112 of thebase structure 110 of the oral care implement 100. Thus, the firstmaterial is rigid to ensure that the oral care implement 100 can behandled without bending or flexing during use. The term rigid materialdoes not mean that the material can not bend at all because allmaterials will bend if a sufficient force is applied thereto. Rather,the term rigid material refers to a hard material that resistsbending/flexing under normal toothbrushing pressures and forces. Thus,during normal toothbrushing the shell component 120 will retain itsshape without significant flexing or bending. In certain embodiments thefirst material of the shell component 120 may be a hard plastic materialsuch as copolyester, polyethylene terephthalate (PET),styrene-acrylonitrile (SAN), polyurethane, polyethylene, polyamide,cellulosic, acrylic, acrylonitrile butadiene styrene (ABS), or the likeor any of the other materials described above as forming a part of thebase structure 110 of the oral care implement 100. Thus, in embodimentsof the invention the first material of the shell component 120 does notinclude elastomeric materials such as thermoplastic elastomers (TPE),rubbers, or the like.

Furthermore, as noted above, in the exemplified embodiment the shellcomponent 120 is substantially translucent or transparent. Thus,regardless of the degree of translucency/transparency of the shellcomponent 120, the shell component 120 is not opaque so that the shellcomponent 120 can be at least partially seen through. As a result, thecore component 130 is visible through the shell component 120 despitethe core component 130 being substantially or entirely surrounded orencapsulated/enveloped by the shell component 120. In certainembodiments the shell component 120 is completely clear and completelytransparent. In other embodiments the shell component 120 is tinted witha color but is still translucent.

In the exemplified embodiment, the core component 130 comprises a body131 formed of a second material and a plurality of decorative elements132 dispersed throughout or embedded within the body 131. In certainembodiments the second material that forms the body 131 of the corecomponent 130 may also be a rigid material, such as any of the hardplastic materials described above for the first material of the shellcomponent 120. Furthermore, the second material that forms the body 131may be transparent, translucent, or opaque and may include variousdifferent colors as will be discussed in more detail below. Differentdegrees of transparency and different colors can be used for the body131 of the core component 130 to achieve a desired aesthetic.

In FIGS. 1-4A, the shell component 120 is substantially translucent ortransparent so that the core component 130 is visible through the shellcomponent 120. Furthermore, the core component 130 is depicted ingrayscale to indicate that the core component 130 is not transparent,but rather is translucent or opaque and includes a color. Furthermore,the plurality of decorative elements 132 are depicted as having adifferent grayscale than the core component 130 to indicate that thedecorative elements 132 are preferably opaque and may have a differentcolor than the core component 130 so that they are readily visiblethrough and within the core component 130.

In the exemplified embodiment, the plurality of decorative elements 132comprises a plurality of particles that are located within the body 131of the core component 130 and visible through the shell component 120.In certain embodiments, the decorative elements 132 are a plurality ofdiscrete and spaced apart particles. In embodiments wherein thedecorative elements 132 are particles, the particles may be speckles,sparkles, flakes, glitter, microspheres, pearlescent particles, or thelike. The particles may be flat, two dimensional structures or shapedthree-dimensional structures. The particles may take on any desiredshape, including polygonal shapes, round shapes, combinations thereof,or the like. The particles may be formed of any desired material,including elastomeric materials, rigid plastics, wood, glass, metal,sand, or the like. In certain embodiments the particles will have ahigher melting temperature than the material that forms the body 131 sothat the particles retain their shape and do not melt during aninjection molding process that forms the core component 130. The mainpurpose of the particles is aesthetic, and thus any material that may bevisible within the body 131 of the core component 130 to achieve thedesired aesthetic effect can be used for the particles/decorativeelements 132.

In the exemplified embodiment, at least one of the plurality ofdecorative elements 132 forms a part of an outer surface 133 of the corecomponent 130. Thus, the at least one of the plurality of decorativeelements 132 and the body 131 collectively forms the outer surface 133of the core component 130. The at least one of the plurality ofdecorative elements 13 may thus be located at an interface between theshell component 120 and the core component 130. As a result, the atleast one of the plurality of decorative elements 132 is exposed at theouter surface 133 of the core component 130. Specifically, if the shellcomponent 120 were somehow removed, the decorative element(s) 132located at the outer surface 133 of the core component 130 would becompletely exposed rather than being embedded within the material of thebody 132 of the core component 130.

Although described herein as having at least one of the plurality ofdecorative elements 132 forming a part of the outer surface 133 of thecore component 130, in the exemplified embodiment there are many of thedecorative elements 132 so located at the outer surface 133 of the corecomponent 130. Locating at least one, and preferably several or many, ofthe plurality of decorative elements 132 at the outer surface 133 of thecore component 130 ensures that the decorative elements 132 are visible,particularly in instances where the core component 130 is opaque anddecorative elements 132 embedded within the core component 130 may bedifficult if not impossible to see. In this manner, the visual effectsdescribed herein can be achieved even when the core component 130 isopaque.

In certain embodiments the body 131 comprises a first color and at leastone of the particles of the plurality of decorative elements 132comprises a second color that is different than the first color. Thefirst and second colors can be different even if they are differentshades of the same color (i.e., sky blue and steel blue are differentshades of blue; crimson and ruby are different shades of red, etc.).Furthermore, in some embodiments the plurality of decorative elements132 may all be the same color. In other embodiments several of theplurality of decorative elements 132 may be different colors relative toeach other. Furthermore, in some embodiments the body 131 may be coloredand one or more of the decorative elements 132 may be transparent. Incertain embodiments it is merely desirable that the plurality ofdecorative elements 132 are visible through the shell component 120 andthrough/within the body 131 of the core component 130. Thus, the variouscolors and transparencies of the shell component 120, body 131, anddecorative elements 132 can be selected to achieve this aestheticpurpose.

In still other embodiments the elastomeric overlay 160 may have a colorthat is the same as one of the color of the body 131 of the corecomponent 130 or the color of the decorative elements 132 dispersed orembedded within the body 131 of the core component 130. Thus, theelastomeric overlay 160 and the body 131 may be a first color and thedecorative elements 132 may be a second color. Alternatively, theelastomeric overlay 160 and the decorative elements 132 may be a firstcolor and the body 131 may be a second color. In still other embodimentseach of the elastomeric overlay 160, the body 131 and the decorativeelements 132 may be a different color or the same color. Thus, manypermutations and variations are possible to create a desired aestheticeffect.

Referring briefly to FIG. 4B, an alternative embodiment is depicted inwhich some of the plurality of decorative elements 132 a are embeddedwithin the body 131 and/or form a portion of the outer surface 133 ofthe body 131 and others of the plurality of decorative elements 132 bprotrude from the outer surface 133 of the body 131. This can create avisibly appealing three-dimensional appearance of the decorativeelements 132 as they are viewed through the shell component 120. Ineither embodiment (FIG. 4A and/or FIG. 4B), the decorative elements 132may collectively take on a specific shape, such as the shape of atelevision character, the shape of a logo, the shape of a company orindividual's name, or the like. Thus, the decorative elements 132 may beused to convey a message to a consumer or take on an appearance that maybe desirable for children. In some embodiments, the decorative elements132 a embedded within the body 131 and the decorative elements 132 bprotruding from the outer surface 133 of the body 131 may together formthe shape of a character, logo, name, or the like. In other embodiments,the decorative elements 132 may be randomly dispersed within the body131.

Referring to FIGS. 5-7 concurrently, another embodiment of an oral careimplement 200 will be described. The oral care implement 200 is similarto the oral care implement 100 in many respects, and thus features ofthe oral care implement 200 that are similar to or the same as featuresof the oral care implement 100 will not be described in detail herein,it being understood that the description of the similar feature in theoral care implement 100 applies. Some of the features that are notdescribed will be numbered similarly to the similar feature in the oralcare implement 100 except that the 200-series of numbers will be used.Thus, the similar features among the oral care implements 100, 200should be readily apparent based on the numbering used in the drawings.

The oral care implement 200 comprises a base structure 210 having ahandle portion 211 and a head portion 212. Furthermore, the basestructure 210 comprises a shell component 220 and a core component 230,the shell component 220 substantially surrounding the core component230. The shell component 220 and the core component 230 are similar instructure, hardness, and material to the same features described abovein the oral care implement 100 and thus in the interest of brevity thesedetails will be omitted with regard to the oral care implement 200, itbeing understood that the description above is applicable.

The main difference between the oral care implement 200 and the oralcare implement 100 is that the core component 230 of the oral careimplement 200 is substantially transparent rather than being depicted ingrayscale as with the oral care implement 100. Thus, in the oral careimplement 200 the shell component 220 is translucent or transparent andthe core component 230 is substantially translucent or transparent. Inone embodiment, the shell and core components 220, 230 may both becompletely transparent so that all light passes through the shell andcore components 220, 230 without being scattered. In other embodimentsone of the shell and core components 220, 230 may be translucent and nottransparent while the other is transparent or both of the shell and corecomponents 220, 230 may be translucent and not transparent and may betinted with the same, similar, or different colors to achieve a desiredaesthetic effect. Although the core component 230 is identifiable in thedrawings due to the line outlining the boundary of the core component230, in practice the core component 230 may blend in completely with theshell component 220 so that a consumer can not tell that there are twodifferent components forming the base structure 210 of the oral careimplement 200. This is particularly true when both the shell and corecomponents 220, 230 are transparent or otherwise formed of a materialhaving an identical color.

In this embodiment, the core component 230 comprises a body 231 and aplurality of decorative elements 232 dispersed or embedded within thebody 231. Thus, to a user who can not visually see the distinctionbetween the shell component 220 and the core component 230, it appearsthat the decorative elements 232 are freely suspended within the basestructure 210 but are limited to some parts of the base structure 210rather than being dispersed throughout the entirety of the basestructure 210. Specifically, the decorative elements 232 are locatedwithin the body 131 of the core component 230 and not also within theshell component 220, so the decorative elements 232 are only visible inparts of the base structure 210 that include the core component 230.Thus, the decorative elements 232 appear to be freely suspended withinsome portions of the handle portion 211 of the base structure 210 butnot within other portions of the handle portion 211 or the head portion212 of the base structure 210.

Referring now to FIGS. 8-10 concurrently, another embodiment of an oralcare implement 300 will be described. The oral care implement 300 issimilar to the oral care implement 100 in many respects, and thusfeatures of the oral care implement 300 that are similar to or the sameas features of the oral care implement 100 will not be described indetail herein it being understood that the description of the similarfeature in the oral care implement 100 is applicable. Some of thefeatures that are not described will be numbered similarly to thesimilar feature in the oral care implement 100 except that the300-series of numbers will be used. Thus, the similar features among theoral care implements 100, 300 should be readily apparent based on thenumbering used in the drawings.

The oral care implement 300 comprises a base structure 310 having ahandle portion 311 and a head portion 312. Furthermore, the basestructure 310 comprises a shell component 320 and a core component 330.The details of the shell component 320 are the same as that describedabove with regard to the shell component 120. Thus, the shell component320 may be transparent or translucent and formed of a rigid material.The shell component 320 substantially surrounds and encapsulates thecore component 330 such that no portion of the core component 330extends to an outer surface 313 of the base structure 310. Rather, theentire outer surface 313 of the base structure 310 is formed by theshell component 320. The shell component 320, and not the core component330, forms the head portion 312 of the base structure 310.

The core component 330 comprises a body 331 and a plurality ofdecorative elements 332. The body 331 is formed of a rigid material andmay be transparent, translucent, opaque, or the like as described hereinabove. The main difference between the oral care implement 300 and thepreviously described oral care implements 100, 200 is that thedecorative elements 332 in this embodiment are not particles, but ratherthey are gas bubbles or void spaces within the body 331. Thus, the body331 may be an opaque material and the decorative elements 332 may be gasbubbles or void spaces within the opaque body 331 so that the gasbubbles or void spaces are readily visible to a consumer or user of theoral care implement 300. Such gas bubbles or void spaces are formed intothe core component 330 by incorporating a foaming agent into the rigidmaterial that forms the body 331 before injecting the rigid material ofthe body 331 into a mold cavity during an injection molding process.Examples of foaming agents that may be used in the practice of thepresent invention include, without limitation, Exocerol AB40E™,Hydrocerol™, or the like. When a foaming agent such as those notedherein above is included into the rigid material of the body 331, as therigid material is heated to an elevated temperature (such as thetemperatures reached during injection molding), the foaming agentgenerates a gas. Thus, as the rigid material with the foaming agentincorporated therein is injected into a mold cavity of a mold, thefoaming agent will form gas bubbles or void spaces within the rigidmaterial of the body 331. These gas bubbles or void spaces are visibleto a user through the shell component 320, thereby forming thedecorative elements 332 of the body component 330.

Incorporating a foaming agent into the material of the body 331 cancreate a desirable aesthetic effect by having the body 331 formed withgas bubbles/void spaces therein that are visible through the shellcomponent 320. The gas bubbles/void spaces will be limited in locationto regions of the base structure 310 that include the core component330, which achieves a unique affect to a viewer or consumer. When thedecorative elements 332 are gas bubbles/void spaces, it may be desirablefor the body 131 to be colored, opaque, translucent, or simply nottransparent so that the gas bubbles/void spaces are readily visiblewithin the body 131. Of course, the invention is not to be so limited inall embodiments and in certain other embodiments the body 131 may betransparent and the decorative elements 332 may be gas bubbles/voidspaces.

Turning now to FIG. 11, a method of forming the base structure 110 ofthe oral care implement 100 of FIGS. 1-4A using a first mold 500 will bedescribed. The base structure 110 of the oral care implement 100 may beformed in a single mold (i.e., the first mold 500) using a sandwichmolding process as described herein. Alternatively, the base structure110 may be formed by overmolding a first solid shot with a separatelymolded second shot, but such process would require two mold cavitiesinstead of one.

In the exemplified embodiment, the first mold 500 comprises a first moldhalf 501 and a second mold half 502, although the invention is not to beso limited in all embodiments and more than two portions may make up thefirst mold 500 in other embodiments. The first and second mold halves501, 502 collectively define a first mold cavity 503 within which thebase structure 110 of the oral care implement 100 is formed as describedherein below. The first mold cavity 503 has a size and shape thatcorresponds with a size and shape of the base structure 110 of the oralcare implement 100 that is formed in the first mold cavity 503 of thefirst mold 500. In the exemplified embodiment, there is a firstinjection sub-system 504 and a second injection sub-system 505 forinjecting different materials into the first mold cavity 503 in separateprocessing steps either simultaneously or sequentially. The firstinjection sub-system 505 includes a first reservoir 516 containing afirst material to be injected and a first conduit 517 that forms apassageway from the first reservoir 516 into the first mold cavity 503so that the first material can be injected into the first mold cavity503 to form the shell component 120 of the base structure 110 of theoral care implement. The second injection sub-system 505 includes asecond reservoir 518 containing a second material to be injected and asecond conduit 519 that forms a passageway from the second reservoir 518to the first mold cavity 503 so that the second material can be injectedinto the first mold cavity 503 to form the core component 130 of thebase structure 110 of the oral care implement 100.

Referring to FIG. 12, the first mold 500 is illustrated with a firstmaterial 506 being injected into the first mold cavity 503 via the firstinjection sub-system 504. In this embodiment the first material 506 is arigid plastic material in molten form due to it being injected at anelevated temperature. In certain embodiments the first material 506 is asubstantially translucent rigid plastic material. The first material 506forms the shell component 120 of the base structure 110 of the oral careimplement 100. Thus, the first material 506 is injected into the firstmold cavity 503 in a desired volume.

Referring to FIG. 13, after a desired volume of the first material 506is injected into the first mold cavity 503, the injection of the firstmaterial 506 is terminated and a second material 507 is injected intothe first mold cavity 503 via the second injection sub-system 505. Thesecond material 507 will form the body 131 of the core component 130 ofthe base structure 110. Specifically, the second material 507 isinjected into the first material 506 in the first mold cavity 503. Asthe second material 507 is injected into the first material 506, thesecond material 507 displaces the first material 506 within the firstmold cavity 503 and the second material 507 becomes surrounded orencased by the first material 506. The first and second materials 506,507 together form the base structure 110 of the oral care implement 100.More specifically, the first material 506 forms the shell component 120of the base structure 110 and the second material 507 forms the corecomponent 130 of the base structure, the shell component 120 surroundingthe core component 130 as described above.

Furthermore, as can be seen in FIG. 13, the plurality of decorativeelements 132 are dispersed within the second material 507 as the secondmaterial 507 is injected into the first mold cavity 503. Thus, after thefirst and second materials 506, 507 are injected into the first moldcavity 503 and cooled to harden, the decorative elements 132 areembedded within the body 131 of the core component 130 formed by thesecond material 507. Because the first material 506 is substantiallytranslucent, the plurality of decorative elements 132 are visiblethrough the first material 506 of the shell component 120 in thecompleted base structure 110. As can also be seen, the first material506 forms the shell component 120 of the base structure 110 and the headportion 112 of the base structure 110.

In the embodiment exemplified in FIGS. 11-13, the plurality ofdecorative elements 132 are particles as described herein above.Furthermore, the second material 507 may be transparent, translucent, oropaque to create a desired aesthetic effect. Although FIGS. 11-13 aredescribed herein wherein the decorative elements 132 are particles thatare dispersed within the second material 506 before the second material506 is injected into the first mold cavity 503, the invention is not tobe so limited in all embodiments. In certain other embodiments, thedecorative elements 132 may be gas bubbles or void spaces formed withinthe second material 507 during injection of the second material 507 intothe first mold cavity 503. Specifically, in such embodiments the secondmaterial 507 may include a foaming agent such that during injectionmolding the second material 507 is heated to a sufficient temperature sothat the foaming agent generates gas that forms the gas bubbles/voidspaces within the second material 507 as described above. Thus, thedecorative elements 132 may be particles dispersed within the secondmaterial 507 prior to injecting the second material 507 into the firstmold cavity 503 or gas bubbles that are formed during the injection ofthe second material 507 into the first mold cavity 503.

After the first and second materials 506, 507 are injected into thefirst mold 500 and allowed to cool and harden, the base structure 110 iscompletely formed. At this stage, the base structure 110 can be removedfrom the first mold 500 and tooth cleaning elements can be attached tothe head portion 112 of the base structure 110 to form a finishedtoothbrush product. Alternatively, the base structure 110 may be used asa hairbrush, razor, or the like as discussed herein above.

In certain embodiments, the base structure 110 may be removed from thefirst mold cavity 503 of the first mold 500 and placed within a secondmold cavity 603 of a second mold 600 wherein a third material may beinjected onto the base structure 110 to form a grip for the oral careimplement 100. Referring to FIG. 14, the base structure 110 ispositioned within the second mold cavity 603 of the second mold 600.While the base structure 110 is so positioned, a third material 606 isinjected into the second mold cavity 603 to fill in the spaces of thesecond mold cavity 603 that are not filled by the base structure 110. Incertain embodiments, the third material 606 may be a thermoplasticelastomer or other elastomeric material to form the elastomeric overlay160 for functioning as a grip on the base structure 110 as noted hereinabove. FIG. 15 illustrates the oral care implement 100 including thebase structure 110 comprising the first material 506 that forms theshell component 120 and the second material 507 that forms the corecomponent 130 and also including the third material 606 that forms theelastomeric overlay 160 coupled to the base structure 110. At this pointin the manufacturing process, the oral care implement 100 can be removedfrom the second mold 600 and finalized for sale by adding tooth cleaningelements, hair brush bristles, or the like to the oral care implement100 before packaging and transport to retail locations.

While the invention has been described with respect to specific examplesincluding presently preferred modes of carrying out the invention, thoseskilled in the art will appreciate that there are numerous variationsand permutations of the above described systems and techniques. It is tobe understood that other embodiments may be utilized and structural andfunctional modifications may be made without departing from the scope ofthe present invention. Thus, the spirit and scope of the inventionshould be construed broadly as set forth in the appended claims.

What is claimed is:
 1. An implement comprising: a base structurecomprising a core component and a shell component, the shell componentencapsulating the core component and forming an outer surface of thebase structure; the shell component formed of a substantiallytranslucent first material; the core component comprising a body formedof a rigid material and a plurality of decorative elements embeddedwithin the rigid material, at least one of the plurality of decorativeelements forming a portion of an outer surface of the core component,the at least one of the plurality of decorative elements of the corecomponent being visible through the substantially translucent firstmaterial of the shell component; and wherein the plurality of decorativeelements comprises discrete particles.
 2. The implement according toclaim 1 further comprising a grip component formed of a thermoplasticelastomer overmolded to the outer surface of the base structure.
 3. Theimplement according to claim 2 wherein the core component, the pluralityof decorative elements, and the grip component are the same color ordifferent shades of the same color.
 4. The implement according to claim1 wherein the body is opaque.
 5. The implement according to claim 1wherein the body is transparent or translucent and the plurality ofdecorative elements are opaque.
 6. The implement according to claim 1wherein the shell component is formed of a rigid material.
 7. Theimplement according to claim 1 wherein the at least one of the pluralityof decorative elements is located at an interface between the shellcomponent and the core component.
 8. The implement according to claim 1wherein the at least one of the plurality of decorative elements isexposed at the outer surface of the core component.
 9. The implementaccording to claim 1 wherein at least one of the plurality of decorativeelements protrudes from an outer surface of the body of the corecomponent.
 10. The implement according to claim 1, wherein the basestructure is a handle of a toothbrush.
 11. An implement comprising: abase structure comprising a core component and a shell componentsurrounding the core component; the shell component and a body of thecore component being formed of a substantially transparent first rigidmaterial; and the core component comprising a plurality of decorativeelements embedded within and dispersed throughout the body and visiblethrough the shell component and the body of the core component; andwherein the shell component is free of any decorative elements.
 12. Theimplement according to claim 11 wherein the plurality of decorativeelements comprises discrete particles.
 13. The implement according toclaim 11, wherein the base structure is a handle of a toothbrush. 14.The implement according to claim 13 wherein the shell component of thebase structure also forms a head of the toothbrush.
 15. The implementaccording to claim 14 further comprising a plurality of tooth cleaningelements extending from the head of the toothbrush.
 16. A method offorming an implement comprising: a) providing a first mold that definesa first mold cavity, the first mold cavity having a shape thatcorresponds with a shape of a base structure of the implement; b)injecting a first material into the first mold cavity, the firstmaterial being transparent or translucent; and c) injecting a secondmaterial into the first material in the first mold cavity, therebydisplacing the first material within the first mold cavity and formingthe base structure, the second material forming a core component of thebase structure and the first material forming a shell component of thebase structure that surrounds the core component; and wherein aplurality of decorative elements are dispersed throughout the secondmaterial of the core component and visible through the first material ofthe shell component.
 17. The method of claim 16 wherein at least one ofthe plurality of decorative elements forms a portion of an outer surfaceof the core component.
 18. The method according to claim 16 wherein thesecond material is opaque and comprises a foaming agent, and wherein theplurality of decorative elements comprises gas bubbles that are formedwithin the second material from the foaming agent during step c). 19.The method according to claim 16 wherein the plurality of decorativeelements comprises discrete particles that are dispersed within thesecond material prior to step c).
 20. The method according to claim 19wherein the second material is opaque.